Bluerock Tools 4"Z1 CORE DRILL MACHINE Quick start guide

OPERATIONAL MANUAL
MODEL: 4”Z1 CORE DRILL MACHINE USED BY HAND
OR WITH OPTIONAL DRILLING RIG
by BLUEROCK ® Tools
Volume
1.3

MWS-
4”Z1 CORE DRILL
UNPACKING THE ITEM
CAUTION: This machine is packed together with items that may be sharp, oily and overly
heavy objects. Remove the machine from the packaging in a safe manner. Check to ensure
all accessories are included with the item while unpacking. If any parts are found to be
missing, contact the retailer as soon as possible. Do not throw away the packaging until the
item is out of the guarantee period. Dispose of the packaging in an environmentally
responsible manner. Recycle if possible. Keep all plastic bags away from children due to risk
of suffocation.
WEEE - Waste Electrical & Electronic Equipment. Note this machine should be disposed of as electrical & electronic waste.
SLURRY DISPOSAL
NOTE: It is recommended to dispose of the drilling slurry (the muddy/dusty water material) in
an environmentally responsible manner. The disposal of slurry directly into sewage
systems, sewers, lakes, rivers, or direct earth without treatment can be environmentally
harmful and possibly illegal. Ask your local public authorities about current regulations in
your area.
ãTHE NEWMAN TRADING COMPANY LLC DBA BLUEROCK® TOOLS 2020
1033 Andover Park East, Tukwila WA 98188 USA
Phone [phone] • Fax [phone]
www.bluerocktools.com

4”Z1 CORE DRILL
Table of Contents
SAFETY' 1!
PRE-OPERATIONAL SAFETY CHECKS! 1!
OPERATIONAL SAFETY CHECKS! 1!
HEALTH WARNINGS! 3!
SPECIFICATIONS' 4!
INCLUDED'ACCESSORIES' 4!
ADDITIONAL'AVAILABLE'ACCESSORIES' 5!
ADDITIONAL ACCESSORIES FOR THIS MACHINE CAN BE FOUND IN BLUEROCK ® TOOLS ONLINE SHOP AT
WWW.BLUEROCKTOOLS.COM OR FROM YOUR LOCAL RETAILER.! 5!
OPERATIONS' 6!
PURPOSE! 6!
OPERATIONAL PRINCIPLES! 6!
MACHINE COMPONENTS! 7!
TRANSPORTING THE MACHINE! 8!
RUNNING THE MACHINE USING THE HANDHELD DRILLING METHOD! 8!
RUNNING THE MACHINE USING THE OPTIONAL DRILLING RIG!10!
INSTALLING CORING BITS!12!
TROUBLESHOOTING'13!
GENERAL'MAINTENANCE'14!
OCCASIONAL'MAINTENANCE'14!
PARTS'LIST'16!
BREAKDOWN'VIEW'-'OVERVIEW'18!
BREAKDOWN'VIEW'–'GEARBOX/MOTOR'CLOSE-UP'19!
BREAKDOWN'VIEW'–'OPTIONAL'DRILLING'RIG'CLOSE-UP'21!

4”Z1 CORE DRILL
1
Safety
DO NOT USE THIS MACHINE UNLESS YOU HAVE READ THE OPERATING
INSTRUCTIONS!
Safety glasses must be worn at all times
in work areas.
Long and loose hair must be
contained.
Appropriate footwear must be worn.
Close fitting/protective clothing
must be worn.
Safety gloves should be worn at all
times and jewelry must not be worn.
Hearing protection should be
worn when using this machine.
Hard-hat must be worn while using
machine.
Dust mask must be worn while
using this machine.
Read operational manual prior to use.
PRE-OPERATIONAL SAFETY CHECKS
Ø Examine the power cord and plug for damage. This tool is supplied with a ground plug and
must always be used with the proper grounded circuit.
Ø Examine the body of the machine and inspect for damage or defects.
OPERATIONAL SAFETY CHECKS
Ø ONLY to be operated by qualified personal who have read instructions.
o NOTE: Failure to read and follow instructions could result in electrical shock, fire,
property damage and/or serious injury!
Ø DO ensure all non-essential people are clear of the immediate work area.
Ø DO be attentive at all times. Keep your eye on the work piece. Always be in a sensible state
of mind and do not use the machine if you cannot fully concentrate.
Chapter
1

4”Z1 CORE DRILL
2
Ø DO keep body parts, clothing & power cords clear of turning/cutting pieces. Stay alert and
use common since when using this tool.
Ø DO allow machine to reach operating speed before starting a hole.
Ø DO unplug machine while changing or adjusting cutting bits so as not to accidentally turn
machine on.
Ø DO remove adjusting wrenches prior to turning the machine on.
Ø DO guard against electric shock by only operating this tool on a properly functioning GFCI
(Ground Fault Circuit Interrupt) circuit.
Ø DO be mindful that power tools can expose an operator to vibrations transmitted trough
contact with the machine. Prolonged exposure can lead to medical issues which should be
discussed with a medical professional.
Ø DO tie in a drip loop in the power cord to prevent water from running into the power
receptacle.
Ø DO use a dust extraction system for cutting materials that create dust. The operator should
also wear a protective respiratory device.
Ø DO NOT make adjustments to machine while the machine is running.
Ø DO NOT switch off the machine when it is under load, except in an emergency.
Ø DO NOT remove or modify grounding plug. Only to be used on a properly grounded GFCI
circuit.
Ø DO NOT leave the machine running when not in use.
Ø DO NOT hold the work piece by hand or using body. Always mechanically clamp or secure
work piece.
Ø DO NOT allow operator to make contact with grounded surfaces such as metal objects.
Ø DO NOT allow liquids to enter the machine’s ventilation system.
Ø DO NOT operate machine outside of machine specifications.
Ø DO NOT touch moving parts while the machine is running as death or dismemberment could
occur.
Ø DO NOT operate machine overhead (Inverted) when drilling “wet” type cores.
Ø DO NOT remove machines electrical components while connected to a power source. Only to
be removed for service by qualified personal and put back on the machine after service is
complete.
Ø DO NOT allow children or untrained personal to operate machine.
Ø DO NOT use this machine in the rain or a wet environment.
Ø DO NOT operate in the presence of explosive materials as power tools create sparks which
may ignite dust or fumes.
Ø DO NOT drill into an area that may contain a live electrical wire/circuit.

4”Z1 CORE DRILL
3
Ø DO NOT use this machine without safely securing to the work piece being drilled.
Ø DO NOT use full water pressure when drilling with “wet” type bits! You need minimal water to
drill with these machines. Extreme water pressure can cause water to enter the gearbox!
Ø DO NOT operate this machine on a lower voltage as it may result in reduced power level and
the machine could become unstable while cutting. This could also limit the motor life.
o NOTE: Use of long small gauge power extension cords can result in decreased
voltage. As local voltages can vary, it may be a good idea to test the voltage at the
end of the extension cord to ensure proper voltage requirements are met. You might
also consult an electrician to make sure the length of cord matches up with the proper
wire gauge for this size motor. Make sure to use outdoor cords when operating
outdoors.
HEALTH WARNINGS
Ø Certain dust created by drilling contains chemicals known to cause cancer, birth defects or
other reproductive harm. The examples of these chemicals are below:
o Lead from lead based paint.
o Crystalline silica from bricks, cement and assorted masonry products.
§ TO REDUCE RISK OF EXPOSURE TO THESE CHEMICALS, WORK IN A WELL
VENTILATED AREA WITH VACUUM SYSTEMS, RESPIRATORS AND WITH
ALL SUITABLE SAFETY EQUIPMENT.

4”Z1 CORE DRILL
4
Specifications
ELECTRICAL DATA
Voltage
110V, 50-60Hz, Single Phase
Current
13 Amps (20A Circuit Use Recommended)
Motor Size
1500W
Power Connection
US Standard 3 Prong Type B Plug
MECHANICAL DATA
Cutter Range
1” to 4” Max Diameter
Cutting Speed
950/2100 RPM Two Speed Gearbox
1) Gear 2 (2100 rpm) for 1”-2” Holes
2) Gear 1 (950 rpm) for 2”-4” Holes
Tool Holder
Direct Arbor 1-1/4” 7 UNC Spindle
Safety Clutch
Yes
Water hose and Valve
Yes
Hand held capable
Yes
Drilling rig capable
Yes (Drill Rig Sold Separately)
SHIPPING DATA
Shipping Weight
22 Lbs
Shipping Carton
19” x 6” x 15”
Included Accessories
DESCRIPTION
QTY
Instruction Manual
1
Water Hose and Valve
1
Spare Brushes (set)
1
Chapter
2

4”Z1 CORE DRILL
5
Note
UPON RECEIPT, CHECK CAREFULLY TO ENSURE THAT THE
MACHINE IS IN GOOD CONDITION AND HAS ALL ACCESSORIES
LISTED ABOVE.
Additional Available Accessories
Additional accessories for this machine can be found in BLUEROCK ® Tools
online shop at www.bluerocktools.com or from your local retailer.
DESCRIPTION
4” Z1 Drill Rig Stand (to be used with this 4” Z1 core drill)
1” Wet Coring Bit
1.25” Wet Coring Bit
1.5” Wet Coring Bit
1.75” Wet Coring Bit
2” Wet Coring Bit
2.5” Wet Coring Bit
3” Wet Coring Bit
3.5” Wet Coring Bit
4” Wet Coring Bit
1” Dry Coring Bit
1.25” Dry Coring Bit
1.5” Dry Coring Bit
1.75” Dry Coring Bit
2” Dry Coring Bit
2.5” Dry Coring Bit
2.75” Dry Coring Bit
3” Dry Coring Bit
3.5” Dry Coring Bit
4” Dry Coring Bit
1-1/4” 7 UNC to 5/8” 11 UNC Core Bit Adapter
10” Extension Rod
12” Extension Rod
18” Extension Rod

4”Z1 CORE DRILL
6
Operations
Note
THOROUGHLY READ THROUGH THE ENTIRE MANUAL BEFORE
OPERATING THIS MACHINE!
PURPOSE
Ø The purpose of the 4”Z1 core drill is to drill through masonry, concrete or other
mineral rock types using annular coring bits.
Ø These drills are designed to be used by hand or bolted to the drilling surface using an
optional drilling rig.
o NOTE: If using the optional drilling rig, make sure the base fits completely on
the surface and the base is securely fastened using wedge anchors to bolt to
the surface.
Ø These machines can be used vertically, horizontally or overhead (inverted) provided
an acceptable work environment. NOTE: For safety, when drilling horizontally or
overhead with the optional drilling rig, a safety chain/strap should always be used.
o CAUTION: If drilling overhead you are only permitted to use dry type core bits
with a vacuum system. “Wet” type holes overhead would allow water into the
motor and create an extremely dangerous situation.
OPERATIONAL PRINCIPLES
Ø The main drilling shaft rotates in a forward clockwise direction. The main drilling
motor connects to the tool spindle to make contact with a surface and slowly bore a
hole. If using the optional drilling rig, the drill fits inside the C clamp assembly and
using the feed handles on the side of the rig, the user can raise or lower the drilling
motor.
Ø These drills are ONLY to be used with diamond impregnated coring bits.
o When drilling with “wet” type bits, the bit ends pulverizes the material and the
water brings the material out of the cut.
o When drilling with “dry” type bits, the bit end pulverizes the material and dust
brings the material out of the cut.
Chapter
3

4”Z1 CORE DRILL
7
MACHINE COMPONENTS
Ø The main components of the 4”Z1 are the spindle, gearbox and motor. Optional
drilling rig consists of a carriage, stand and base. The spindle is driven by the
transfer case and the motor.
o These components must be not be removed except by a qualified technician.
Power must be disconnected prior to any service.
o If using the optional drilling rig, this machine has one primary adjusting point
for the travel between the drill carriage and the drill stand. The main way to
increase or decrease the users ability to move the drill by hand is with this
system. These are the black hex bolts on the side and back of the machine
that have a locking nut around them. These are generally used to tighten up
the travel as the slides wear over time. Be mindful to evenly adjust these so
that the travel is even and smooth. The ideal travel generally keeps the drill in
place when the user is not using the drill (this is usually on the tighter side)
although individual users needs may vary. The side black carriage bolt can
also be used for temporarily locking the carriage in place.
MACHINE MOUNTED IN OPTIONAL DRILLLING RIG
1) Top Bolt for Binding in Ceilings
2) Motor End Cap Level
3) Motor “On” Hold Button
4) Drill Motor
5) Drill Carriage
6) Motor On/Off Switch
7) Gearbox
8) Feed Handle
9) Water Valve
10) Drill Stand
11) Coring Bit (not included)
12) Stand Leveling Bolts
13) Stand Base
14) Gear Shifter
15) Gear 1
16) Gear 2
17) C Clamp Assembly

4”Z1 CORE DRILL
8
MACHINE AS HAND HELD UNIT
TRANSPORTING THE MACHINE
Ø When transporting the machine, always use two hands.
Ø DO NOT transport the machine with bits in the spindle.
Ø If transporting inside a vehicle, it is recommended to transport it on its side so as to
avoid the item falling over.
Ø DO NOT carry the machine by the cord.
Ø DO NOT allow the cord or plug to drag along the floor when transporting.
RUNNING THE MACHINE USING THE HANDHELD DRILLING METHOD
Ø Do all pre-operational and operational safety checks from Chapter 1.
Ø Disconnect the machine from the drilling rig by unbolting the C clamp assembly and
sliding the drill upwards out of the drilling rig.
Ø Consider your security and stability as well as the orientation of the machine in the
work area.
o DO NOT use this item in an unstable position (such as on a ladder, leaning
outside of center of gravity, etc). When using by hand, these drills could bind
up and personal injury could occur if not taking into account a very stable
body position.
o Consider the work surface material, condition, strength, density and rigidity.
These factors directly affect the tools efficiency.
Ø Ensure the secondary drill handle is securely attached.
Ø Ensure the work surface is free of debris, oil, etc.
Ø If using “wet” type bits, set up your drilling templates or other professional methods
for starting your hole.
Ø Select and set up fluid delivery method or dust collection system.
1) Gear Shifter
2) Shoulder Rest
3) 1-1/4” Drill Spindle
4) Drill Motor
5) Secondary Drill Handle
6) Motor On/Off Switch
7) Tightening Nut for Secondary
Handle

4”Z1 CORE DRILL
9
Ø If using the machine with the water system, connect hose to the side of the machine
using the connector.
o This connector takes standard ¾” US garden hose hookup.
o Make sure the water valve is in the off position.
§ This is generally at a 90 degree angle from the valve hose.
o Partially turn the water spigot on (usually half a turn).
§ CAUTION: DO NOT turn the hose on fully! You need sufficient water
when using wet type bits. Using too much water pressure can cause
the bits to not cut properly as well as water entering the gearbox.
Ø Select appropriate size cutting bit and install by screwing the bit onto the spindle.
See section below for details on securing bit.
Ø Plug the machine into power source.
o Form a loose knot in the power cord close to the plug connection to prevent
fluid from running down the cord and into the power receptacle.
Ø Select the gear you will be using.
o Do not force the gear shifter when changing between gears. There is a
neutral position between gear 1 and gear 2.
o Change gears when the machine is stopped or almost stopped.
Ø Open the water valve to allow water to come out to the work surface.
Ø Turn the machine on by engaging the motor into the “on” position.
o CAUTION: When using the machine by hand, it is not recommended to use
the machine with the motor switch “hold” position engaged. It is
recommended to only use the finger trigger switch.
Ø ATTENTION: BE AWARE THESE MACHINES ARE EXTREMELY POWERFUL. THEY
HAVE A TREMENDOUS AMOUNT OF TORQUE WHICH MIGHT NOT BE SUITABLE
FOR ALL POTENTIAL USERS. ESPECIALLY IN LOW GEAR AND WITH LARGER BITS.
DESPITE THE SAFETY CLUTCH, THESE DRILLS CAN STILL INJURE THE USER. IF IN
DOUBT, CONTACT A PROFESSIONAL FOR ADVICE.
Ø Very slowly engage the cutting bit with the material surface by lightly engaging the
bit with the material.
o NOTE: During the initial stages of contact the bit may wander.
o NOTE: If wet drilling and not using a guide, a common way to start the hole
uses a 30 degree angle to slightly cut into the material. Once the bit has
bored slightly into the material, the user will slowly level the machine out
straightly. If unsure, it is recommended to contact a coring professional.
Ø After about 1/8” of cutting has been achieved in the work surface, slightly more force
can be applied. This will be the normal amount of force the rest of the hole.
o NOTE: Do not force the hole. Let the machine do most of the work.
Excessive physical effort should be avoided as it can cause damage to the
machine or cause injury to the user.

4”Z1 CORE DRILL
10
o If the unit jams in a hole, stop the drill immediately by quickly disengaging the
“on” switch to prevent injury. Disconnect the drill from the power supply and
loosen the cutter by turning drill spindle counterclockwise. Never attempt to
free bit by starting motor!
§ After an interruption in drilling, make sure the drill bit is free and turns
before restarting the hole. Be very careful at this point to make certain
the drill does not bind when restarting.
o CAUTION: CAUTION: It can take a 1-2 seconds for the safety clutch to engage
otherwise excessive wear and heat will develop.
Ø Make sure to keep the cutting material lubricated when “wet” drilling.
Ø Ease up on pressure as the cutter starts breaking through the backside of the
material.
o Be certain all is clear on the output side of this core to prevent injury to
persons or property.
Ø Finish drilling the hole.
Ø Turn the motor off and disconnect power once the drill is safely back to the non-
drilling position.
Ø Turn water valve off.
RUNNING THE MACHINE USING THE OPTIONAL DRILLING RIG
Ø Do all pre-operational and operational safety checks from Chapter 1.
Ø Consider your security and stability as well as the orientation of the machine in the
work area.
o Consider the work surface material, condition, strength, density and rigidity.
These factors directly affect the tools efficiency.
Ø Ensure the drill is secure in the drilling assembly by inspecting the C clamp assembly
and checking the tension on the C clamp bolts.
o Ensure the machine’s axis are parallel with the drill stand.
Ø Secure the machine base to the work surface by using a wedge anchor or other
method to ensure the base does not move.
Ø Use the four leveling bolts on the corners of the base to level the machine.
Ø After placing the machine in work area, connect a safety chain or strap if necessary.
o The safety chain should attach to the machine (preferably through the
carrying handle or O bolt) as well as attached to the work area in such a
manner that prevents the machine from detaching or falling from the work
area.
Ø Ensure the feed handles are securely attached to the feed spindle.
Ø Ensure the work surface is free of debris, oil, etc.
Ø Select the gear you will be using.

4”Z1 CORE DRILL
11
o Do not force the gear shifter when changing between gears. There is a
neutral position between gear 1 and gear 2.
o Change gears when the machine is stopped or almost stopped.
Ø Select and set up fluid delivery method or dust system.
Ø If using the machine horizontally with the water system, connect hose to the side of
the machine using the connector.
o This connector takes standard ¾” US garden hose hookup.
o Make sure the water valve is in the off position.
§ This is generally at a 90 degree angle from the valve hose.
o Partially turn the water spigot on (usually half a turn).
§ CAUTION: DO NOT turn the hose on fully! You need sufficient water
when using wet type bits. Using too much water pressure can cause
the bits to not cut properly as well as water entering the gearbox.
Ø Select appropriate size cutting bit and install. See section below for details on
securing bit.
Ø Check that the machine is firmly attached to the work area.
Ø Plug the machine into power source.
o Form a loose knot in the power cord close to the plug connection to prevent
fluid from running down the cord and into the power receptacle.
Ø Turn feed handle raising the cutter until the bit is above the work surface.
Ø Open the water valve to allow water to come out to the work surface.
Ø ATTENTION: BE AWARE THESE MACHINES ARE EXTREMELY POWERFUL. THEY
HAVE A TREMENDOUS AMOUNT OF TORQUE WHICH MIGHT NOT BE SUITABLE
FOR ALL POTENTIAL USERS. ESPECIALLY IN LOW GEAR AND WITH LARGER BITS.
DESPITE THE SAFETY CLUTCH, THESE DRILLS CAN STILL INJURE THE USER. IF IN
DOUBT, CONTACT A PROFESSIONAL FOR ADVICE.
Ø Turn the machine on by engaging the motor into the “on” position.
o If wanting the machine to continue in the “on” position, engage the hold
button on the side of the handle above the finger “on” switch. To disengage
the motor when in the hold function, quickly depress the finger “on” switch to
turn the motor off. You may want to cycle through this sequence a couple
times before using the machine for the first time to familiarize the user with
this process.
Ø Very slowly engage the cutting bit with the material surface by lightly engaging the
hand crank down towards the material.
o NOTE: During the initial stages of contact the bit may wander.
Ø After about 1/8” of cutting has been achieved in the work surface, slightly more force
can be applied. This will be the normal amount of force the rest of the hole.

4”Z1 CORE DRILL
12
o NOTE: Do not force the hole. Let the machine do most of the work.
Excessive physical effort should be avoided as it can cause damage to the
machine or the user.
o If the unit jams in a hole, stop the drill immediately by quickly depressing the
“on” switch to prevent injury. Disconnect the drill from the power supply and
loosen the cutter by turning drill spindle counterclockwise. Never attempt to
free bit by starting motor!
§ After an interruption in drilling, make sure the drill bit is free and turns
before restarting the hole. Be very careful at this point to make certain
the drill does not bind when restarting.
o CAUTION: It can take a 1-2 seconds for the safety clutch to engage otherwise
excessive wear and heat will develop.
Ø Make sure to keep the cutting material lubricated.
Ø Ease up on feed pressure as the cutter starts breaking through the backside of the
material.
o Be certain all is clear on the output side of this core to prevent injury to
persons or property.
Ø Finish drilling the hole.
Ø Turn the motor off and disconnect power once the drill is safely back up in the non-
drilling position.
Ø Turn water valve off.
Ø Unbolt the wedge anchor.
Ø Disconnect safety chain/strap and move the drill to a new drilling location.
INSTALLING CORING BITS
Ø WARNING: Core bits can be sharp and should only be handled with gloves so as not
to cut the user during installation or removal.
Ø Check that the bits are not damaged.
o Coring bits that are damaged should not be used.
Ø Make certain the machine is unplugged from power.
Ø If using the drilling rig, raise the drill motor to ensure ample room to install the bit.
o Apply grease to the spindle thread to prevent corrosion and allow easier core
bit removal.
Ø Insert the coring bit and screw it onto the drill spindle.
Ø Tighten the bit until fully tightened.
o Use wrenches that fit the spindle and coring bit to fully tighten.

4”Z1 CORE DRILL
13
Troubleshooting
Note
SERVICING SHOULD ONLY BE DONE BY A QUALIFIED TECHNICIAN.
DON’T FORGET TO UNPLUG POWER TO UNIT PRIOR TO SERVICE!
PROBLEM
SOLUTION
Motor does not
turn on.
1) Check external power source (extension cord, breaker, etc).
2) Loose internal wire. Check and secure if necessary.
3) Motor brushes defective. Replace if necessary.
4) Check to ensure the motor on/off switch is operable. Replace if
necessary.
Excessive
sparking when
motor is running.
1) This may indicate the presence of debris in the motor or worn out carbon
brushes. Check the brushes for unusual wear and replace if necessary.
Clean out the internal motor armature if necessary.
2) Armature has a rough edge. Inspect and replace if necessary.
Hole is not
cutting.
1) Cutting bit is dull. Replace bit.
2) Work area material is not appropriate for bit type.
Bit is jammed
while coring.
1) Debris is lodged between core hole and bit. Rotate bit in both directions
to and inspect bit for debris.
2) If using the drilling rig, make sure the base is secured to the work surface.
Coring speed has
reduced.
1) Bit has hit rebar. Adjust feed pressure to prevent motor overload while
cutting through rebar.
2) Diamonds on bit have glazed over. Deglaze bit or dress diamond rim on
bit and check water flow rate.
3) Diamonds on bit have worn away. Replace core bit.
4) New core bit. Core at slow rate with new bits for 2-3 coring cycles.
5) The safety clutch is slipping. Tighten clutch.
6) Drilling progress is prevented by an accumulation of dust. Use suitable
vacuum cleaner.
7) Water flow rate is too low. Increase water flow.
8) Core is stuck in the core bit. Remove core.
Core bit appears
to wobble.
1) Spindle is damaged. Replace spindle and check bearings.
2) Bit is bent or damaged. Replace bit.
3) The core bit is not screwed securely onto the spindle.
4) Coring material is attaching to the bit. Inspect bit and increase water flow
rate.
Water escapes at
the water swivel
or gear housing.
1) The water pressure is too high. Turn down water flow.
2) The shaft seal is defective. Replace seal
3) The water hose is damaged. Replace hose.
Chapter
4

4”Z1 CORE DRILL
14
General Maintenance
Ø Inspect electrical cords and electrical connections.
Ø Keep machine clean and free of debris. Do not forget to grease the drill spindle.
Ø Check for misalignment, binding and breakage of all moving parts. If damaged, repair tool
before use.
Ø Keep cutting tools sharp and clean. Sharp bits are less likely to bind and are easier to
control.
Occasional Maintenance
Ø Have the power tool serviced by a qualified service technician using identical replacement
parts.
o Change motor brushes:
1) Disconnect drill from power.
2) Open rear motor cover.
3) Take out old brushes.
o If you need to, use the screw driver to nudge them out.
4) Replace with exact same size new brushes.
o Adjusting Carriage on Optional Drilling Rig:
1) Periodically check and adjust slides as necessary.
2) Use hex wrench to loosen the lock nuts and hex screws.
3) Adjust the screws evenly while moving the handle up and down so
that there’s no free play yet not binding anywhere through its range of
travel.
4) Retighten the lock nuts.
o Change Gear Oil:
1) Change if necessary using NLGL-2 grade grease. This service is
generally done around the 50 hour service mark.
Chapter
5

4”Z1 CORE DRILL
15
o Adjust Safety Clutch:
1) Adjust clutch as necessary.
o NOTE: A torque wrench is necessary for this service.
o Make certain the spindle is facing the ground so as not to get
oil/grease everywhere. Locate the hex screws holding the gear
housing together and remove them.
o Gently pull the gear housing apart. You may use a couple flat
screwdrivers to gently apply pressure to separate the
housings.
o Take the main clutch nut off of the clutch. Apply some Loctite
type of thread glue on the clutch threads.
o Reapply the nut to the thread.
o Hold the spindle in place using the box wrench. See diagram
below.
o Use the torque wrench to tighten the clutch nut.
o Torque the tensioning nut to 13 NM (115 inch/lbs, 9.5 ft/lbs).
ATTENTION: BE AWARE THESE MACHINES ARE EXTREMELY
POWERFUL. THEY HAVE A TREMENDOUS AMOUNT OF
TORQUE, WHICH MIGHT NOT BE SUITABLE FOR ALL
POTENTIAL USERS- ESPECIALLY IN LOW GEAR WITH
LARGER BITS. DESPITE THE SAFETY CLUTCH, THESE
DRILLS CAN STILL INJURE THE USER. IF IN DOUBT,
CONTACT A PROFESSIONAL FOR ADVICE.
o With the clutch nut tightened, reassemble the housings. Make
sure the orientation of the internal gears is correct and the
housings mate correctly.
o Reattach the bolts that hold the housing together.

4”Z1 CORE DRILL
16
Parts List
4"Z1 Core Drill (Not Including Optional Stand)
#
Spec
Name
#
Spec
Name
#
Spec
Name
#
Spec
Name
1
02-
80/001
Output shaft
28
φ17
Unmark
uncork
shielding
for shaft
55
φ4
Flat washer
82
02-
80/068
Handle bracket
cover board
2
φ4
Stell ball
29
HK121
0
Quill
bearing
56
02-
80/201
Stator
assembly
83
ST2.9×16
Crossed slot
tapping bolt
3
02-
80/050
Small spring
3.6×14.5×12
30
M16×3
5
Butterfly
nut
57
02-
80/022
Stator
insulating
cover
84
M5×35
Inner
hexagonal roud
head bolt
4
A5×32
Flat key
31
02-
80/045
Assistant
handle
58
02-
80/023
Insulating
shim
85
06-
80/020
Left handle
5
φ47×1.5
Spring shield
ring for holes
47
32
M14×4
5
Hexagonal
bolt
59
02-
80/033
Name plate
86
02-
80/067
Inductance
6
KS-NS
K60052Z
Deep groove
of ball
bearing
33
KS-
NSK629
Deep
groove ball
bearing
60
2×4
Scutcheon
rivet
87
Capacitance0.3
3uF+3300PF
7
φ25×1.2
Shield ring
for shaft
34
02-
80/004
3#gear
shaft
61
02-
80/034
Scutcheon
88
Switch
8
02-
80/041
Shim cover
35
02-
80/009
Butterfly
spring
62
02-
80/015
Shell of drill
89
06-
80/019
Right handle
9
FB25×40
×7
Bracket
rubber
sealing ring
36
02-
80/049
Preforming
63
3×6
Mushroom
head rivets
90
ST4.2×19
Crossed slot
tapping bolt
10
02-
80/044
Assistant
handle cover
37
02-
80/008
Friction
plate
64
02-
80/025
Brush-
holder base
plate
91
ST4.2×16
Crossed slot
tapping bolt
11
M5×75
Inner
hexagonal
round head
bolt
38
02-
80/007
Copper
cover
65
M3×6
Crossed slot
bolt
92
02-
80/029
Cable press
board
12
M5×55
Inner
hexagonal
round head
bolt
39
02-
80/003
2#gear
66
02-
80/047
Brush
assembly
93
02-
80/031
Jacket
13
φ5
Spring
washer
40
02-
80/010
Press ring
67
02-
80/028
Coil spring
94
PRCD (optional)
14
φ5
Flat washer
41
M12×1.
25
Hexagonal
nut
68
Brush frame
assembly
95
Cable & Plug
15
02-
80/002
Reducer
casing
42
02-
80/040
Spacer
69
M14
Hexagonal
nut
96
02-
80/060
Washer for
water faucet
16
φ3×20
O-shape
sealing ring
43
HK101
0
Quill
bearing
70
02-
80/024
Rear cover
jacket
97
02-
80/062
Connector of
water faucet
17
φ5×16
Round pin
44
φ78×2
O-shape
sealing ring
71
φ30×2.
5×35
O-shape
sealing ring
98
02-
80/061
Tightening
screw
18
φ3×12
Column pin
45
02-
80/014
Middle
cover
72
02-
80/016
Rear cover
99
02-
80/065
Tightening ring
19
M5×12
Inner
hexagonal
46
02-
80/037
Sealing oil
ring
73
02-
80/017
Rear handle
base
100
Inner φ8×350
mesh tube
Chapter
6

4”Z1 CORE DRILL
17
round head
bolt
20
02-
80/012
Adjustable
speed block
47
02/80/
053
Oil sealing
base shim
74
02-
80/018
Rear handle
101
02-
80/063
Connector of
water faucet
21
02-
80/013
Adjustable
speed knob
48
NSK620
1
Deep
groove ball
bearing
75
M15×4
0
Inner
hexagonal
round head
bolt
102
02-
80/043
Mini ball valve
22
FB20×35
×7
Bracket
rubber
sealing ring
49
02-
80/101
Armature
assembly
76
02-
80/051
Level pole
103
02-
80/064
Connector of
water switch
23
02-
80/058
Oil sealing
(φ24×φ18×0.
8）
50
02-
80/052
Armature
insulating
rear cover
77
M4×6
Crossed slot
bolt
104
11.2×2.6
5×16.5
O-shape sealing
ring
24
02-
80/006
6#gear
51
NSK620
0
Deep
groove ball
bearing
78
02-
80/039
Handle
lining
105
02-
80/038
Rear cover
25
02-
80/006-
1
Copper
cover
52
02-
80/035
Shield
board
79
02-
80/021
R
Handle
bracket
26
φ18×1
Shield ring
for shaft
53
M14×1
05
Cross slot
bolt
80
Post bead
DG8H-0
27
02-
80/005
4# gear
54
φ4
Spring
washer
81
ST2.9×
9.5
Crossed slot
Apping bolt
4"Z1 Optional Drilling Rig
#
Spec
Name
#
Spec
Name
1
M8×30
Inner hexagonal round head bolt
27
Stand pole groupware
2
φ8
Spring ring
28
Z3Z-CF-180-27
Rod
3
02-80/036
Rear handle base
29
M8×10
Flying rings bolt
4
10×8×100
Flat Key
30
M5×8
Lock bolt catch
5
CF-180-07
Lift
31
CF-180-07/1
Lift body cover
6
M14
Acorn nut
32
CF-180-34
Rotate wheel
7
φ4
Spring washer
33
CF-180-33
Shaft pin
8
φ4
Flat washer
34
φ10
Cir clips for shaft
9
CF-180-39
Stop knob
35
Cable press board assembly
10
M4×16
Crossed countersunk head bolt
36
CF-180-32
Base
11
CF-180-07/2
Screw
37
M16
Hexagonal nut
12
M8
Thin hexagonal nut
38
M16×75
Hexagonal bolt
13
M8×16
Inner hexagonal round head bolt
39
M8×20
Screw
14
CF-180-07/6
Orbit strip
40
M6×30
Inner hexagonal round head bolt
15
CF-255/3-14
Ellipse handle cover
41
CF-180-07/3
Handle of lift body
16
CF-180-28
Operating stick for machine
42
M6×20
Inner hexagonal round head bolt
17
CF-180-29
Sleeve operating stick
43
φ10
Spring washer
18
Sleeve fasten assembly
19
M4×6
Crossed countersunk head bolt
20
CF-180-07/4
Orbit strip
21
CF-180-07/5
Orbit strip
22
φ8
Flat washer
23
M12×65
Inner hexagonal head bolt
24
φ17×1
Cir clips for shaft
25
6003Z
Deep groove ball bearing
26
Z3Z-CF-180-16
Operating gear wheel axle